1GR-FE ENGINE MECHANICAL EM-27 - Pure FJ Cruiser

1GR-FE ENGINE MECHANICAL – TIMING CHAINEM–27INSTALLATIONPushStopper Plate1.INSTALL CHAIN TENSIONER SLIPPER2.INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY(a) While turning the stopper plate of the tensionerclockwise, push in the plunger of the tensioner asshown in the illustration.(b) While turning the stopper plate of the tensionercounterclockwise, insert a bar of φ 35 mm (0.138 in.)into the holes in the stopper plate and tensioner tofix the stopper plate.(c) Install the chain tensioner with the 2 bolts.Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf)3.INSTALL CHAIN SUB-ASSEMBLY(a) Set the No. 1 cylinder to TDC/ compression.(1) Align the timing marks of the camshaft timinggears and bearing caps.Stopper PlateA076294E02Bank 1:Bank 2:Timing MarksTiming MarksTiming MarksG036290E06(2) Using the crankshaft pulley set bolt, turn thecrankshaft to align the crankshaft set key withthe timing line of the cylinder block.Timing LineSet KeyA076296E02EM

EM–281GR-FE ENGINE MECHANICAL – TIMING CHAIN(b) Align the yellow mark link with the timing mark of thecrankshaft timing link.Mark LinkTiming MarkA076297E03(c) Align the orange mark links with the timing marks ofthe camshaft timing gears, and install the chain.Mark Links4.INSTALL NO. 2 CHAIN VIBRATION DAMPER(a) Install the 2 No. 2 chain vibration dampers.5.INSTALL IDLE SPROCKET ASSEMBLY(a) Apply a light coat of engine oil to rotating surface ofthe No. 1 idle gear shaft.EMTiming MarksG036259E02(b) Temporarily install the No. 1 idle gear shaft togetherwith the No. 2 idle gear shaft with the knock pin ofthe No. 1 idle gear shaft and the knock pin groove ofthe cylinder block are aligned.NOTICE:Orient the idle gear shafts correctly.(c) Using a 10 mm hexagon wrench, tighten the No. 2idle gear shaft.Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf)(d) Remove the bar from the chain tensioner.ForwardKnock PinA076299E026.INSTALL TIMING GEAR CASE OR TIMING CHAINCASE OIL SEAL (See page EM-163)7.INSTALL TIMING CHAIN OR BELT COVER SUBASSEMBLY(a) Remove any old packing (FIPG) material.HINT:Do not drop any oil on the contact surfaces of thetiming chain cover, cylinder head and cylinder block.(b) Install a new O-ring onto the bank 2 cylinder headas shown in the illustration.G036305E01

1GR-FE ENGINE MECHANICAL – TIMING CHAINEM–29(c) Apply continuous beads of seal packing (diameter 3to 4 mm (0.12 to 0.16 in.)) to the 4 locations shownin the illustration.Seal packing:Toyota Genuine Seal Packing Black, ThreeBond 1207B or the equivalentSeal PackingG036306E01(d) Keep the seal surface between the cylinder blockand the cylinder head shown in the illustration freeof oil before installing the chain cover.EMA126368Seal PackingABWater PumpPartBWater Pump Part3 to 4 mmSeal PackingSeal Width 3 to 4 mm3 to 4 mm3 to 4 mm(e) Apply continuous beads of seal packing (diameter 3to 4 mm (0.12 to 0.16 in.)) to the timing chain coveras shown in the illustration.Seal packing:Water pump part:Toyota Genuine Seal Packing 1282B, ThreeBond 1282B or the equivalentOther parts:Toyota Genuine Seal Packing Black, ThreeBond 1207B or the equivalentNOTICE: Install the timing chain cover within 3 minutesof applying the seal packing. The timing chaincover bolts and nuts must be tightened within15 minutes of the installation. Otherwise theseal packing must be removed and reapplied. Do not apply seal packing to portion A shownin the illustration.16.7 mmB - B’A076303E04(f)15 qA076304E01Align the key way of the oil pump drive rotor with therectangular portion of the crankshaft timing gear,and slide the timing chain cover into place.

EM–301GR-FE ENGINE MECHANICAL – TIMING CHAINAAABBBBNutBABBBB B(g) Install the timing chain cover with the 24 bolts and 2nuts. Tighten the bolts and nuts uniformly in severalsteps.Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)NOTICE:Pay attention not to wrap the chain and slipperover the timing chain cover seal line.Each bolt length is as followsAABBBABBNutAAG036303E02EMBoltLengthA25 mm (0.98 in.)B55 mm (2.17 in.)8.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLYLH (See page EM-57)9.INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY(See page EM-58)10. INSTALL WATER INLET (See page CO-9)11. INSTALL VVT SENSOR (See page ES-417)12. INSTALL CAMSHAFT TIMING OIL CONTROL VALVEASSEMBLY (See page ES-415)13. INSTALL IGNITION COIL ASSEMBLY (See page IG-8)14. INSTALL INTAKE AIR SURGE TANK (See page FU17)15. INSTALL NO. 2 SURGE TANK STAY (See page FU-19)16. INSTALL NO. 1 SURGE TANK STAY (See page FU-19)17. INSTALL OIL BAFFLE PLATE (See page FU-19)18. INSTALL THROTTLE BODY BRACKET (See page FU19)19. INSTALL AIR CLEANER ASSEMBLY (See page ES431)20. INSTALL OIL PAN SUB-ASSEMBLY(a) Remove any old packing (FIPG) material.HINT:Do not drop any oil on the contact surfaces of thecylinder block, rear oil seal and oil pan.(b) Install a new O-ring onto the oil pump.A076452E01

EM–311GR-FE ENGINE MECHANICAL – TIMING CHAINSealPackingSeal Width: 3 to 4 mmBAABG036801E01BACAAACBBNutB B Nut BBG036833E01Flywheel HousingUnder Cover(c) Apply a continuous bead of seal packing (diameter3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shownin the illustration.Seal packing:Toyota Genuine Seal Packing Black, ThreeBond 1207B or the equivalentNOTICE:Install the oil pan within 3 minutes of applyingthe seal packing. Tighten the oil pan bolts andnuts within 15 minutes of installing the oil pan.Otherwise, the seal packing must be removedand reapplied.(d) Install the oil pan with the 17 bolts and 2 nuts, andtighten the bolts and nuts uniformly in several steps.Torque: 10 mm (0.39 in.) head10 N*m (102 kgf*cm, 7.4 ft.*lbf)12 mm (0.47 in.) head21 N*m (214 kgf*cm, 16 ft.*lbf)Nut21 N*m (1,214 kgf*cm, 16 ft.*lbf)HINT:Each bolt length is as follows:BoltLengthA25 mm (0.98 in.)B45 mm (1.77 in.)C14 mm (0.55 in.)(e) Install the 4 housing bolts.Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)(f) Install the flywheel housing under cover.A076446E0121. INSTALL OIL STRAINER SUB-ASSEMBLY(a) Install a new gasket and the oil strainer with the 2nuts.Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)22. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY(a) Remove any old packing (FIPG) material.HINT:Do not drop any oil on the contact surfaces of the oilpan and No. 2 oil pan.A072951E01EM

EM–321GR-FE ENGINE MECHANICAL – TIMING CHAINSeal PackingSeal Width: 3 to 4 mmA076308E02(b) Apply a continuous bead of seal packing (diameter3 to 4 mm (0.12 to 0.16 in.)) as shown in theillustration.Seal packing:Toyota Genuine Seal Packing Black, ThreeBond 1207B or the equivalentNOTICE:Install the No. 2 oil pan within 3 minutes ofapplying the seal packing. Tighten the No. 2 oilpan bolts and nuts within 15 minutes ofinstalling the No. 2 oil pan. Otherwise, the sealpacking must be removed and reapplied.(c) Install the No. 2 oil pan with the 10 bolts and 2 nuts.Tighten the bolts and nuts uniformly in severalsteps.Torque: Bolt9.0 N*m (92 kgf*cm, 80 in.*lbf)Nut10 N*m (102 kgf*cm, 7.4 in.*lbf)EMA072949E0123. INSTALL CRANKSHAFT PULLEY(a) Using SST, install the pulley set bolt.SST 09213-54015 (91651-60855), 09330-00021Torque: 250 N*m (2,549 kgf*cm, 184 ft.*lbf)SSTA076309E0224. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY(a) Install the idler pulley with the bolt.Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)HINT:DOUBLE is marked on the No. 1 idler pulley todistinguish it from the No. 2 idler pulley.“DOUBLE”A076438E01

EM–331GR-FE ENGINE MECHANICAL – TIMING CHAIN25. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY(a) Install the 2 No. 2 idler pulleys with the 2 bolts.Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)A076338E0126. INSTALL VANE PUMP ASSEMBLY(a) Install the vane pump with the 2 bolts.Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)NOTICE:Do not hit the pulley with other parts wheninstalling the vane pump.(b) Connect the power steering pressure switchconnector.A076444E02O-RingPush27. INSTALL OIL LEVEL GAUGE GUIDE(a) Install a new O-ring onto the oil level gauge guide.(b) Apply a light coat of engine oil to the O-ring.(c) Push the oil level gauge guide end into the guidehole in the oil pan.(d) Install the oil level gauge guide with the bolt.Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)(e) Install the oil level gauge guide.A076314E0228. INSTALL V-RIBBED BELT TENSIONER ASSEMBLYNOTICE:The bolt in position A is not reusable.HINT:Each bolt length is as follows:ABCEDA076445E03PositionLengthA70 mm (2.76 in.)B, C, D and E33 mm (1.30 in.)(a) Use a new bolt in position A.(b) Finger-tighten the bolts in positions A and E andinstall the bracket.(c) Tighten the bolts in positions A and E.Torque: 36 N*m (267 kgf*cm, 27 ft.*lbf)(d) Tighten the bolts in positions B, C and D.Torque: 36 N*m (267 kgf*cm, 27 ft.*lbf)29. INSTALL COOLER COMPRESSOR ASSEMBLY (Seepage ES-421)30. INSTALL GENERATOR ASSEMBLYRefer to the procedures up to "INSTALL GENERATORASSEMBLY" (See page CH-17)EM

EM–341GR-FE ENGINE MECHANICAL – TIMING CHAIN31. INSTALL FANRefer to the procedures up to "INSTALL FAN PULLEY"(See page CO-17).32. INSTALL FRONT DIFFERENTIAL CARRIERASSEMBLY (for 4WD)Refer to the procedures up to "INSTALL FRONTDIFFERENTIAL CARRIER ASSEMBLY" (See page DF42).33. INSTALL POWER STEERING LINK ASSEMBLY (for2WD)Refer to the procedures up to "INSTALL POWERSTEERING LINK ASSEMBLY" (See page PS-30).EM34. INSTALL POWER STEERING LINK ASSEMBLY (for4WD)Refer to the procedures up to "INSTALL POWERSTEERING LINK ASSEMBLY" (See page PS-49).35. INSTALL BATTERY36. ADD ENGINE COOLANT (See page CO-3)37. ADD ENGINE OIL (See page LU-5)38. ADD POWER STEERING FLUID39. BLEED POWER STEERING FLUID (See page PS-2)40. ADD DIFFERENTIAL OIL (for 4WD)41. INSPECT DIFFERENTIAL OIL (for 4WD) (See pageDF-3)42. CHECK FOR ENGINE COOLANT LEAKAGE (Seepage CO-4)43. CHECK FOR ENGINE OIL LEAKAGE44. CHECK FOR POWER STEERING FLUID LEAKAGE45. CHECK FOR DIFFERENTIAL OIL LEAKAGE46. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page SP-2)

EM-28 1GR-FE ENGINE MECHANICAL - TIMING CHAIN EM (b) Align the yellow mark link with the timing mark of the crankshaft timing link. (c) Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain. 4. INSTALL NO. 2 CHAIN VIBRATION DAMPER (a) Install the 2 No. 2 chain vibration dampers. 5.